Expandable liner system

ABSTRACT

A system comprises a tubular releasably coupled to a launcher. An expansion assembly is sealingly engaged with the tubular so that the expansion assembly is moved longitudinally through the tubular by applying a pressurized fluid to the launcher. The expansion assembly radially expands the tubular as it moves longitudinally therethrough. A valve is coupled to the expansion assembly and opens when fluid pressure within an unexpanded portion of the tubular exceeds fluid pressure within the launcher. An extending member is coupled to the expansion assembly and to the launcher. The extending member restricts longitudinal movement of the expansion assembly relative to the launcher once the tubular is radially expanded.

CROSS-REFERENCE TO RELATED APPLICATIONS

None

BACKGROUND

This disclosure relates generally to the construction, maintenance, and repair of wellbore tubular strings to facilitate hydrocarbon production or downhole fluid injection. In particular, this disclosure relates to methods and apparatus for radially expanding a solid tubular member within a wellbore.

During hydrocarbon exploration and production, a wellbore typically traverses a number of zones within a subterranean formation. Efficient completion of the wellbore or production from the surrounding formation is highly dependent on the inner diameter of the tubular system installed in the wellbore. Greater inner diameters of the tubular string allows inserted equipment and fluids with appropriate pressure ratings to be used in well completions, while also allowing increased production of hydrocarbons thereafter.

Expandable tubing may be used to maximize the inner diameter of casing, liners and other similar downhole tubular strings used as described above. To create a casing, for example, a tubular member is installed in a well bore and subsequently expanded by displacing an expansion device through the tubular member. As the expansion device is displaced axially within the tubular member, the expansion device imparts radial force to the inner surface of the tubular member. The expansion device may be axially displaced by mechanical means, such as by a support tubular coupled thereto, or driven by hydraulic pressure. In response to the radial force exerted by the expansion device, the tubular member plastically deforms, thereby permanently increasing both its inner and outer diameters. In other words, the tubular member expands radially.

Expandable tubulars may also be used to repair, seal, or remediate existing casing that has been perforated, parted, corroded, or damaged since installation. While many prior art systems for installing expandable tubulars are designed for installing an extended length of tubular, in certain applications only a short length of tubular is required to be expanded. When installing a short length of expandable tubular, a system designed to install longer lengths may be cumbersome or economically inefficient. There is a continuing need in the art for systems for quickly and reliably installing shorter lengths of expandable tubular into a wellbore.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more detailed description of the embodiments of the present disclosure, reference will now be made to the accompanying drawings, wherein:

FIG. 1 is schematic view of an expandable liner system shown in an as run position;

FIG. 2 is a schematic view of the expandable liner system of FIG. 1 shown in an equalization mode;

FIG. 3 is a schematic view of the expandable liner system of FIG. 1 shown with the liner fully expanded;

FIG. 4 is a schematic view of the expandable liner system of FIG. 1 shown as certain components are being recovered from the wellbore;

FIG. 5 is schematic view of an alternative embodiment of an expandable liner system shown in an as run position;

FIG. 6 is a schematic view of the expandable liner system of FIG. 5 shown in an equalization mode;

FIG. 7 is a schematic view of the expandable liner system of FIG. 5 shown with the liner fully expanded; and

FIG. 8 is a schematic view of the expandable liner system of FIG. 5 shown as certain components are being recovered from the wellbore.

DETAILED DESCRIPTION

In the drawings and description that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present disclosure is susceptible to embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results.

Unless otherwise specified, any use of any form of the terms “connect”, “engage”, “couple”, “attach”, or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. The terms “pipe,” “tubular member,” “liner,” “casing,” and the like as used herein shall include tubing and other generally cylindrical objects. In addition, in the discussion and claims that follow, it may be sometimes stated that certain components or elements are in fluid communication. By this it is meant that the components are constructed and interrelated such that a fluid could be communicated between them, as via a passageway, tube, or conduit. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.

Referring initially to FIG. 1, liner system 10 comprises launcher 12, tubular 14, and expansion assembly 16. Liner system 10 is designed to install tubular 14 into wellbore 44 by using expansion assembly 16 to radially expand the tubular. Hydraulic pressure applied to launcher 12 acts to move expansion assembly 16 downward, radially expanding tubular 14. Expansion assembly 16 is coupled to launcher 12 so that, once tubular 14 is fully expanded, the launcher and the expansion assembly can be released from the tubular and retrieved from wellbore 44.

Launcher 12 includes housing 18, support member 20, annulus port 22, sleeve 24, sleeve retainer 26, and sleeve seals 28. Support member 20 is coupled to the upper end of housing 18 and serves as a conduit for the supply of pressurized fluid to liner system 10. Support member 20 may be drill pipe, coiled tubing, or other conduit that is coupled to a supply of pressurized fluid, which may be located at the surface or in wellbore 44, such as a submersible pump. Launcher 12 also comprises annulus port 22 that provides selective fluid communication between the interior of housing 18 and wellbore 44. Sleeve 24 is shown in a position covering annulus port 22 with sleeve seals 28 providing sealing engagement between the sleeve and launcher 12 so as to prevent fluid communication through the annulus port. Sleeve retainer 26 is positioned within launcher 12 so as to limit the longitudinal travel of sleeve 24.

Extendable member 42 is coupled to expansion assembly 16 and sleeve 24. Extendable member 42 allows expansion assembly 16 to move through tubular 14 but restricts the movement of the expansion assembly once the tubular is fully expanded. Extendable member 42 is illustrated in FIGS. 1-4 as a flexible member such as a wire rope or cable.

Launcher 12 is coupled to tubular 14 by releasable connection 30. In certain embodiments, releasable connection 30 is a threaded connection that allows disconnection by rotating launcher 12 relative to tubular 14. Releasable connection 30 may also be other types of connections that allow for disconnection by rotation, axial pull, or other means that allow for disconnection while liner system 10 is disposed in wellbore 44. In certain embodiments, sealing members 32 are coupled proximate to the ends of tubular 14 to facilitate sealing engagement with wellbore 44.

Expansion assembly 16 comprises expansion cone 34, packer cup 36, equalization port 38, and equalization valve 40. In the position shown in FIG. 1, expansion assembly 16 is partially disposed within launcher 12. Expansion assembly 16 is adapted to sealingly engage launcher 12 and/or the inner diameter of tubular 14 through packer cup 36 and/or expansion cone 34. This sealing engagement fluidicly isolates the interior of launcher 12 above expansion assembly 16 from the interior of tubular 14 below the expansion assembly, thus allowing a pressure differential to be developed across the expansion assembly.

Equalization port 38 provides fluid communication across expansion assembly 16. Equalization valve 40 controls fluid flow through equalization port 38. Equalization valve 40 has a closed position (see FIG. 1) that prevents the flow of fluid through equalization port 38 when the pressure within launcher 12 exceeds the pressure within tubular 14. Equalization valve 40 also has an open position (see FIG. 2) that allows the flow of fluid through equalization port 38 when the pressure within launcher 12 is less than the pressure within tubular 14. Equalization valve 40 may be a flapper valve, check valve, or other type valve that supports flow in one direction through the valve.

FIGS. 1-4 illustrate the operation of liner system 10, which will be discussed in detail to follow. FIG. 1 shows liner system 10 in an expansion mode with tubular 14 in position to be installed in wellbore 44. FIG. 2 shows liner system 10 in an equalization mode with tubular 14 partially installed in wellbore 44. FIG. 3 shows tubular 14 completely expanded in wellbore 44 with launcher 12 and expansion assembly 16. FIG. 4 shows launcher 12 and expansion assembly 16 being removed from wellbore 44, leaving tubular 14 fully installed.

Referring first to FIG. 1, liner system 10 is disposed in wellbore 44 at a desired depth. Fluid is pumped into launcher 12 via support member 20. Expansion assembly 16 is sealingly engaged with launcher 12 such that pressurized fluid in the launcher creates a pressure differential across the expansion assembly. The pressure differential across expansion assembly 16 generates a force on the expansion assembly that urges expansion assembly 16 downward. Once a sufficient pressure differential, and thereby force, is generated, expansion assembly 16 moves longitudinally through and radially expands tubular 14.

As expansion assembly 16 moves downward and expands tubular 14, sealing members 32 engage wellbore 44. The continued downward movement of expansion assembly 16 tends to increase the fluid pressure in the wellbore below the expansion assembly. As the fluid pressure increases below expansion assembly 16 the pressure differential across the expansion assembly will decrease unless pressure within launcher 12 is increased. Because of limitations in the amount of pressure that can be applied to launcher 12, the increase in pressure below expansion assembly 16 will eventually reduce the differential pressure across the expansion assembly to the point that the movement of the expansion assembly, and therefore the expansion of tubular 14 stops.

In certain embodiments, fluid below expansion assembly 16 may be able to flow from wellbore 44 into the surrounding formation, thus reducing the pressure buildup below the expansion assembly. Under some conditions, the flow of fluid into the formation may allow tubular 14 to be completely expanded without having to stop the expansion process to equalize pressure across expansion assembly 16.

When expansion assembly 16 stops moving through expandable tubular 14, or when pressure within launcher 12 exceeds operational limits, liner system 10 can be shifted into an equalization mode, as is shown in FIG. 2. In the equalization mode, valve 40 is in an open position that allows fluid communication across expansion assembly 16 through equalization port 38. Valve 40 is a valve that allows flow in one direction, such as a flapper valve or check valve, and is biased to a closed position. Valve 40 is configured to move to an open position when the pressure below expansion assembly 16 exceeds the pressure above the expansion assembly by a predetermined amount. Valve 40 may be opened by reducing the pressure within launcher 12 or will open automatically when the pressure below expansion assembly 14 exceeds the pressure within the launcher by a predetermined amount.

Valve 40 remains in an open position allowing fluid communication through equalization port 38 until the pressure across expansion assembly 14 equalizes to the point where the valve will return to a closed position, as shown in FIG. 1. Once valve 40 has closed, pressure can be applied to launcher 12 and expansion of expandable tubular 14 can be continued. This cycle of expansion and pressure equalization can be continued until expandable tubular 14 is completely expanded.

Referring now to FIG. 3, expansion assembly 16 has fully expanded expandable tubular 14. When expansion assembly 16 has completed the expansion of tubular 14, extendable member 42 limits the continued movement of the expansion assembly and shifts liner system 10 into a retrieval mode by opening valve 40 and by shifting sleeve 24 so as to opening annulus port 28. The upper end of extendable member 42 is coupled to sleeve 24. Referring back to FIGS. 1 and 2, during the expansion of tubular 14, sleeve 24 is positioned over annulus ports 22, which are isolated from the interior of launcher 12 by seals 28. Once extendable member 42 is fully extended, sleeve 24 moves downward, thus opening annulus ports 22 and providing a fluid path between support member 20 and the annulus. This fluid path allows fluid being pumped through support member 20 to return to the surface via the annulus, signaling the completion of the expansion process. Sleeve 24 continues to move downward until the sleeve contacts sleeve retainer 26, as is shown in FIG. 3, and the downward movement of expansion assembly 16 is stopped.

When the movement of expansion assembly 16 is stopped, expansion cone 34 has moved through the entire length of tubular 14 and the tubular is fully installed in wellbore 44. Launcher 12 can then be disconnected from tubular 14 by disconnecting releasable connection 30. In certain embodiments, releasable connection 30 is disconnected by rotating support member 20 and launcher 12 relative to tubular 14.

Referring now to FIG. 4, once releasable connection 30 is disconnected, launcher 12 and expansion assembly 16 can be retrieved from wellbore 44, leaving expanded tubular 14 in place. As launcher 12 is raised, extendable member 42 pulls expansion assembly into and through tubular 14. In certain embodiments, cone 34 of expansion assembly 16 may have a profiled top edge that serves to guide the cone into the lower end of tubular 14.

FIGS. 5-8 illustrate an alternative liner system 50 comprising launcher 52, liner 54, and expansion assembly 56. Launcher 52 comprises housing 58, support member 60, annulus port 62, sleeve 64, sleeve retainer 66, sleeve seals 68, and releasable connection 70. Expansion assembly 56 comprises expansion cone 74, packer cup 76, equalization port 78, equalization valve 80, and mandrel 82. Valve 80 is a one-way check valve comprising ball 90 and spring 92 that biases the valve into a closed position. Mandrel 82 includes mandrel ports 86 and mandrel flange 88. The upper end of liner 54 is coupled to releasable connection 70 and sealing members 72 are coupled proximate to the ends of the liner.

Referring first to FIG. 5, liner system 50 is disposed in wellbore 84 at a desired depth. Expansion of liner 54 is initiated by pumping fluid into launcher 52 via support member 60 and mandrel ports 86. Pressurized fluid in launcher 52 creates a pressure differential across expansion assembly 56, which generates a force on the expansion assembly that pushes the expansion assembly downward through liner 54, thereby radially expanding the liner.

The continued downward movement of expansion assembly 56 tends to increase the fluid pressure in wellbore 84 below the expansion assembly. As the fluid pressure increases below expansion assembly 56, the pressure differential across the expansion assembly will decrease until the force generated is insufficient to expand liner 54 and the expansion assembly will stop moving. To continue expansion of liner 54, the pressure differential across expansion assembly 56 must be increased by either reducing the pressure below the expansion assembly or increasing the pressure within launcher 52.

In order to reduce the pressure below expansion assembly 56, liner system 50 can be shifted into an equalization mode, as is shown in FIG. 6. To shift liner system 50 into the equalization mode, the pressure within launcher 52 is decreased so that valve 80 moves to an open position that allows fluid communication across expansion assembly 56 through equalization port 78. Valve 80 remains in an open position allowing fluid communication through equalization port 78 until the pressure across expansion assembly 54 equalizes to the point where the valve will return to a closed position, as shown in FIG. 5. Once valve 80 has closed, pressure can be applied to launcher 52 and expansion of liner 54 can be continued. This cycle of expansion and pressure equalization can be continued until liner 54 is completely expanded.

Referring now to FIG. 7, expansion assembly 56 has fully expanded liner 54. As expansion assembly 56 completes the expansion of tubular 54, mandrel flange 88 engages sleeve 64 and shifts the sleeve downward to open annulus port 62. Opening annulus port 62 allows fluid within launcher 52 to return to the surface via the annulus, signaling the completion of the expansion process. The longitudinal movement of mandrel 82 is stopped by sleeve 64 contacting sleeve retainer 66, which also stops the movement of expansion assembly 56. Valve 80 is also opened by the full extension of mandrel 82.

When the movement of expansion assembly 56 is stopped, expansion cone 74 has moved through the entire length of liner 54 and the tubular is fully installed in wellbore 84. Launcher 52 can then be disconnected from liner 64 by disconnecting releasable connection 70. Referring now to FIG. 8, once releasable connection 70 is disconnected, launcher 52 and expansion assembly 56 are retrieved from wellbore 84, leaving liner 44 in place. As launcher 52 is raised, mandrel 82 pulls expansion assembly 56 into and through liner 54.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and description. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the disclosure to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present disclosure. 

1. A system comprising: a housing; a tubular releasably coupled to said housing; an expansion assembly sealingly engaged with said tubular so that said expansion assembly is moved longitudinally through said tubular by applying a pressurized fluid to said housing, wherein said expansion assembly radially expands said tubular as it moves longitudinally therethrough; a valve coupled to said expansion assembly, wherein said valve opens when fluid pressure within an unexpanded portion of said tubular exceeds fluid pressure within said housing; and a extending member coupled to said expansion assembly and said housing, wherein said extending member restricts longitudinal movement of said expansion assembly relative to said housing once said tubular is radially expanded.
 2. The system of claim 1 wherein said extending member comprises a tubular mandrel.
 3. The system of claim 1 wherein said extending member comprises a cable.
 4. The system of claim 1 wherein said valve is a flapper valve.
 5. The system of claim 1 wherein said valve is a ball valve.
 6. The system of claim 1 wherein said housing is releasably coupled to said tubular by a threaded connection.
 7. The system of claim 1 further comprising: an annulus port disposed in said housing; and a sleeve moveably disposed within said housing, wherein said sleeve has a first position preventing fluid communication through said annulus port and a second position allowing fluid communication through said annulus port.
 8. The system of claim 7 wherein said sleeve is coupled to said extending member so that said extending member moves said sleeve from the first position to the second position once said tubular is radially expanded.
 9. A system comprising: a launcher having an upper end coupled to a support member that is operable to supply pressurized fluids to said launcher; a liner releasably coupled to a lower end of said launcher; an expansion assembly coupled to said launcher by an extending member; wherein said expansion assembly is operable to move longitudinally through and radially expand said liner in response to pressurized fluid being supplied to said launcher, and wherein said extending member restricts longitudinal movement of said expansion assembly once said liner is radially expanded; and a valve coupled to said expansion assembly, wherein said valve opens when fluid pressure within an unexpanded portion of said liner exceeds fluid pressure within said launcher.
 10. The system of claim 9 wherein said extending member comprises a tubular mandrel.
 11. The system of claim 9 wherein said extending member comprises a cable.
 12. The system of claim 9 wherein said valve is a flapper valve.
 13. The system of claim 9 wherein said valve is a ball valve.
 14. The system of claim 1 wherein said launcher is releasably coupled to said liner by a threaded connection.
 15. The system of claim 9 further comprising: an annulus port disposed in said launcher; and a sleeve moveably disposed within said launcher, wherein said sleeve has a first position preventing fluid communication through said annulus port and a second position allowing fluid communication through said annulus port.
 16. The system of claim 15 wherein said sleeve is coupled to said extending member so that said extending member moves said sleeve from the first position to the second position once said tubular is radially expanded.
 17. A method comprising: disposing an expansion assembly in sealing engagement with a liner that is releasably connected to a launcher; disposing the launcher, liner, and expansion assembly in a wellbore; applying a pressurized fluid to the launcher so as to generate a differential pressure across the expansion assembly that moves the expansion assembly downward through and radially expands the liner; equalizing the differential pressure across the expansion assembly by opening a equalizing valve disposed in the expansion assembly; closing the equalization valve once the differential pressure across the expansion assembly is equalized; and applying a pressurized fluid to the launcher so as to generate a differential pressure across the expansion assembly that moves the expansion assembly downward through and continues the radial expansion of the liner.
 18. The method of claim 17, further comprising: restricting the movement of the expansion assembly relative to the launcher once the liner has been radially expanded.
 19. The method of claim 18 wherein the movement of the expansion assembly is restricted by an extendable member that is coupled to the launcher and the expansion assembly.
 20. The method of claim 17, further comprising: disconnecting the launcher from the liner; and removing the launcher and the expansion assembly from the wellbore, wherein the expansion assembly is coupled to the launcher by an extendable member. 